Heat Shrink Component With Heat Spreading Layer
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Solution Overview
Problem
Existing heat shrink component installation methods using open flames are unsafe and inefficient, requiring excessive energy and time, and existing electrical heating systems face challenges in achieving uniform heat distribution and preventing material degradation.
Innovation Solution
A heat shrink component with an electrically conductive lead and a heat spreading layer that distributes heat generated by the conductive lead, allowing for efficient and uniform heating using electrical energy, reducing installation time and ensuring even shrinkage without material damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If open flames are used for heat shrink component installation, then heating capability is sufficient, but safety is compromised and energy consumption is excessive
Solution Approach 1:
The patent replaces the mechanical/chemical combustion system (open flames) with an electrical heating system. Electrically conductive leads are embedded in the heat shrink component to generate heat directly through electrical resistance, eliminating the need for external flames and associated safety hazards while maintaining effective heating capability.
Solution Approach 2:
The patent employs periodic or controlled electrical current application to the conductive leads, allowing precise temporal control of heat generation. This enables the heating process to be activated only when needed and deactivated when the desired shrinkage is achieved, improving safety and energy efficiency compared to continuous flame application.
2Temperature
If open flames are used for heat shrink component installation, then heating capability is sufficient, but installation time is excessive
Solution Approach 1:
The electrical heating system generates heat directly within the heat shrink component through the conductive leads, eliminating heat transfer inefficiencies associated with external flames. This internal heat generation achieves faster and more uniform heating, significantly reducing installation time while maintaining sufficient heating capability.
Solution Approach 2:
The heat shrink component with embedded conductive leads is self-heating, generating the required thermal energy internally without external heating equipment. This self-service capability eliminates the time required for external flame application and monitoring, accelerating the installation process.
3Use of energy by moving object
If electrical heating is used without heat spreading layer, then energy efficiency is improved, but heat distribution uniformity deteriorates
Solution Approach 1:
The heat spreading layer acts as an intermediary between the electrically conductive leads and the heat shrink material. It receives heat from the leads and distributes it uniformly across the component, ensuring even heating while maintaining the energy efficiency of electrical heating by preventing localized overheating and reducing total energy requirements.
Solution Approach 2:
The heat spreading layer has spatially varying thermal properties, with higher thermal conductivity regions positioned to distribute heat from the conductive leads uniformly across the heat shrink material. This local optimization of thermal conductivity ensures uniform heat distribution while maintaining overall energy efficiency.
4Speed
If high temperature heating is applied, then shrinkage speed is improved, but material degradation occurs
Solution Approach 1:
The heat spreading layer serves as a thermal mediator that buffers the temperature between the electrically conductive leads and the heat shrink material. It distributes the thermal energy uniformly and prevents localized temperature spikes, enabling fast shrinkage through efficient heat distribution while preventing material degradation through temperature control.
Solution Approach 2:
The electrical heating system with heat spreading layer provides precise thermal control compared to open flames. The heat generation can be precisely controlled through electrical parameters, and the heat spreading layer ensures uniform distribution, enabling rapid shrinkage without the uncontrolled high temperature spikes that cause material degradation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables fast and even heating of heat shrink components, reducing installation time and ensuring uniform shrinkage, thus improving safety and efficiency while preventing material degradation.
Implementation Method 1
The heating unit includes an electrically conductive lead heated by an electrical current flowing through the electrically conductive lead
Implementation Method 2
a heat spreading layer arranged in thermal contact with the electrically conductive lead and distributing a heat generated by the electrically conductive lead
Implementation Method 3
Heat shrink components are articles made from material which shrinks from an expanded state into a shrunk state with much smaller dimensions by applying a sufficient amount of heat
Data Source
AI summary
A heat shrink component includes a heat shrink layer and a heating unit in thermal contact with at least a part of the heat shrink layer and heating the heat shrink layer to a heat shrink temperature. The heat shrink component has a first dimension in an expanded state and a second dimension in a shrunk state after heating, the first dimension is larger than the second dimension. The heating unit includes an electrically conductive lead heated by an electrical current flowing through the electrically conductive lead and a heat spreading layer arranged in thermal contact with the electrically conductive lead and distributing a heat generated by the electrically conductive lead.